OMRON F159 Load Cell Interface - PLC-Based Process Controllers

Small, Fast and Flexible Weigh-based Process Control

Weigh-based Process Control can be established by integrating F159 Special I/O Unit into SYSMAC CJ1. F159 provides direct Load Cell connection.

In addition, it provides pre-programmed functions, e.g. Zero Tracking, Auto Free-fall Compensation and etc. An ideal solution for various process weighing application.

Features

Specifications that can be offered only by the well-versed Unipulse-all mobilized into the a small body, is the new weighing solution High Speed A/D Conversion with High Resolution A 500 times/sec high-speed conversion to counter fluctuations in weight value. Also, when it is set to the 1/4 scale division compliance to the Weight and Measurement Law, it guarantees 1/10000 display resolution at all input range (1/40000 when not set at 1/4 scale division). Its accuracy is most desired by demanding weighing requirements. Weighing Sequence Function By only entering the setting instruction, feeding and discharging gate can be directly controlled. All weighing control is performed by F159 Load Cell Interface to lighten CJ1 load so that a high-speed weighing and control line can be set-up without it being affected by CJ1 command timing. Auto Free-fall Compensation F159 Load Cell Interface automatically compensates fluctuations in actual free fall, which is one of the biggest factors that causes weighing error. Gravitational Acceleration Compensation Even when calibration site and installation site are at different locations, calibration can be completed by just setting the gravitational acceleration of the installation site. There is no further need to perform re-calibration at the installation site. Zero Tracking The slow zero drift, which is caused by temperature fluctuation, and the zero point shift are automatically compensated. Powerful Filters to Eliminate Mechanical Vibrations Installed with Bessel low-pass filter, which has powerful damping characteristics, and moving average-type digital filter.

Weighing Applications

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OMRON PLC CS1W-LCB05-GTC Loop Control Board

Loop Controllers with Fully Integrated Sequence and Loop Control and Built-in Gradient Algorithm for Uniform Temperature Control Across Multiple Points   Inconsistent thermal processing temperatures result in unstable workpieces and reduced yield.   OMRON's unique Gradient Temperature Control technology enables uniform in-plain control of thermal processing temperatures. This not only increases the quality of thermal processing, but also reduces energy loss while the temperature stabilizes and the adjustment time required to eliminate interference caused by heaters.   This has a great impact on batch ovens, glass substrate hot plates, and other precise process control.

What is Gradient Temperature Control?

Gradient temperature control enables controlling the temperature of an object subject to interference at multiple points, such as the multi-point control of surface temperature using multiple heaters. It directly controls the average temperature of all points and the temperature difference between points and also eliminates interference from the control outputs from one point to another.   The temperature for each point is input and the average temperature for all points and the gradient temperature (temperature difference) between each pair of neighboring points is calculated. PID control is performed using each of these values as a process value. PID manipulated variable outputs are distributed to prevent the outputs from affecting other PID control, i.e., to prevent interference. This means that interference from multiple heaters to other measurement points is reduced and the temperature of multiple points can be raised and controlled uniformly.

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OMRON C200HW-PA204C Power Supply Units with Maintenance Forecast Monitor

New PLC Power Supply Units That Let You Know When Unit Replacement Is Necessary.

Features

Schedule Replacement and Replace Units before Their Service Life Ends The Power Supply Unit has a 6-level, 7-segment display on the front to indicate when the Unit should be replaced. It also outputs an alarm when the estimated remaining service life falls below 6 months. This enables Unit replacement before the end of its service life before the system goes down. It also makes it easier to plan Unit replacement, such as the lines or Racks where replacement is necessary and the number of Units to replace.   Same Wiring and Size as Current Power Supply Units Simply replace your current Power Supply Unit to add the maintenance forecast monitor function. The CJ1W-PA205C is the same size as the CJ1W-PA205R and the C200HW-PA204C is the same size as the C200HW-PA204.

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OMRON SYSMAC CS / CJ-series High-speed Data Storage Units

Storage and Processing Units SYSMAC SPU

CS1W-SPU01/02-V2

CJ1W-SPU01-V2 

 

SYSMAC SPU-Host Data Link Software
Data Management Middleware

WS02-EDMC1-V2

 

The SYSMAC SPU reads PLC I/O memory according to specified collection methods and stores the data in CSV (Comma Separated Value) files. The SYSMAC SPU can record a variety of data from equipment using a PLC.   Use the SYSMAC SPU to record data such as production history data, inspection data and process data. Electronically managing data on the operation of equipment and devices enables root cause analysis when error occur, as well as a proper understanding of operational tendencies.

Features

Data Collection Using a PLC Unit PLC data is collected in a PLC Unit with superior environmental resistance without using a computer. Until now, data has been collected in PLC memory. Using an SYSMAC SPU Unit, however, eliminates the need for a PLC with a large-capacity memory and also eliminates the need for programming data collection in the ladder program. CS1W-SPU01/02-V2 CJ1W-SPU01-V2 Fast Collection of Large Amounts of Data with Data Concurrency Using a computer for data collection presents the problems of a slow collection speed and low collection-point capacity. An SPU enables high-speed collection of large amounts of data. Direct use of the PLC bus instead of communications via a serial connection or LAN enables large amounts of data to be collected at a high speed. Some data collection devices from other companies may not provide data concurrency. The SYSMAC SPU Unit, however, provides concurrency of simultaneous data. No Ladder Programming No ladder programming is required for data collection. Data can be collected simply by performing the settings from the setting software (i.e., SPU-Console). No need to leave extra space in the PLC memory for saving data. Note: The PLC cycle time increases in proportion to the number of points collected. Restriction-free Data Configuration Files without Depending on PLC Memory Space Files can be created with the desired data configuration for only the necessary data from PLC memory. The data to be collected can be stored in files in the required data type, such as BOOL, REAL, INT, BCD, or STRING. Data configuration files required for the host computer can be created, so necessary data can be retrieved even if the SPU is mount in a device after the PLC is already set up. CHANNEL_BLOCK has been added to the variable data types from SYSMAC SPU Unit version 2.0. When the data type is set to CHANNEL_BLOCK, the data in a consecutive memory area starting from the specified address for the specified number of elements is handled as a single data item with no commas. Recipe Function The recipe function enables writing numeric data (such as production parameters) and text strings to a memory area of the PLC. Using the recipe-writing function simplifies tasks such as retooling. (Note: The recipe function can be used only in Data Storage Mode.) * Numeric data and text strings to be written to a memory area of the PLC must be created in advance as recipe data (i.e., a CSV file) and stored in a Memory Card in the SYSMAC SPU Unit. Ladder programming for developing recipe data is not required. Using the recipe function saves PLC memory by saving recipe data to a Memory Card in the SYSMAC SPU Unit rather than requiring saving to the PLC data memory. Recipe data can be written in response to a request from the PLC or from a computer or other external device. Numeric data and text strings can be changed even when the SYSMAC SPU Unit is operating. Data Connectivity with the Computer The collected data can be loaded onto a computer via a PC card or Ethernet. Data can be loaded onto the host computer with simple settings by using the Data Management Middleware software. Using shared folders, data files collected in the SYSMAC SPU Unit can be accessed from a LAN-connected Windows computer just as if accessing files on the computer itself. Collection Methods to Match the Application Depending on the application, the Data Storage Mode can be used to collect data at a specific time or when there is a change in data, and the Sampling Mode can be used to accurately collect data at high speed. The Data Storage Mode enables establishing a system for error monitoring and production management for each lot or value by recording snapshots of data during production and when errors occur. Note: The Sampling Mode and Data Storage Mode cannot be used at the same time. Sampling Mode (Previous Function) In this mode, I/O memory data for the PLC is sampled at a constant time interval. Data can be faithfully reproduced from the collected data. Data Storage Mode In this mode, the specified PLC I/O memory can be recorded when triggered by a specific event. The mode can be used to record data when a specified bit turns ON or at a specified time. Data can also continue being recorded at a constant time interval after an event occurs. This enables establishing a system for error monitoring and production management for each lot and value by recording snapshots of data during production or when errors occur. Note: The time interval is less precise than the interval in Sampling Mode. Event-triggered Collection Patterns The patterns include memory events, which occur when a memory value matches a specified condition, and scheduled events, which occur at a specified time or time interval. The occurrence of these events can be used to implement rules, such as those for starting and stopping data collection. (Applicable only in Data Storage Mode.) Memory Events Memory events can be set to generate an event when a change occurs in I/O data in PLC memory. Using memory events, events can be generated for a change in a bit ON/OFF status or by comparison to a set value (i.e., equal, above, below, or within range). For example, data could be collected only once when bit A turns ON. Alternatively, an event rule could be defined to start collection when bit A turns ON and stop collection when bit B turns ON. Scheduled Events Scheduled events can be set to generate an event at a specific date and time using Scheduler settings. Event rules can be defined with Scheduler settings for collecting data as a result of events specified, for example, by the hour (e.g., every hour), day (e.g., every day), or week (e.g., every Monday). It is also possible to specify events by operating days or for the end of the month. Collection Settings Changeable during PLC Operation Collection settings can be changed and collection can be restarted without turning OFF the PLC. Required data can be added and the collection interval can be changed even while the system is operating. Installing an SPU enables adding various systems after the system is already in operation.

 

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OMRON CJ1G-CPU45P-GTC Loop-control CPU Unit

Loop Controllers with Fully Integrated Sequence and Loop Control and Built-in Gradient Algorithm for Uniform Temperature Control Across Multiple Points   Inconsistent thermal processing temperatures result in unstable workpieces and reduced yield.   OMRON's unique Gradient Temperature Control technology enables uniform in-plain control of thermal processing temperatures. This not only increases the quality of thermal processing, but also reduces energy loss while the temperature stabilizes and the adjustment time required to eliminate interference caused by heaters.   This has a great impact on batch ovens, glass substrate hot plates, and other precise process control.

What is Gradient Temperature Control?

Gradient temperature control enables controlling the temperature of an object subject to interference at multiple points, such as the multi-point control of surface temperature using multiple heaters. It directly controls the average temperature of all points and the temperature difference between points and also eliminates interference from the control outputs from one point to another.   The temperature for each point is input and the average temperature for all points and the gradient temperature (temperature difference) between each pair of neighboring points is calculated. PID control is performed using each of these values as a process value. PID manipulated variable outputs are distributed to prevent the outputs from affecting other PID control, i.e., to prevent interference. This means that interference from multiple heaters to other measurement points is reduced and the temperature of multiple points can be raised and controlled uniformly.

Features

Greater Quality with Uniform In-plain Temperature Control ** Click on the picture to enlarge. Gradient Temperature Control Mechanism and Programming Examples   Gradient temperature control finds and controls the relationship between temperatures for mutually interfering points, i.e., it finds the average temperature and the gradient temperatures, which are the temperature differences between points. This type of control achieves uniform in-plan temperatures. ** Click on the picture to enlarge.

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OMRON CJ1W-PA / CJ1W-PD SYSMAC CJ Series Power Supply Units

Equipped with the RUN output for checking the operation status, as well as the replacement notification function for easy maintenance. Lineup of five models including the AC power supply (25W). Stable power supply is available from the CJ-series CPU Unit to each I/O Units via the dedicated bus. The most suitable Power Supply Unit can be selected among various I/O specifications and/or options. The replacement notification function can prevent an overflow of the system due to the power lifetime. (CJ1W-PA205C only) Power Supply Unit provides wide variations according to the system scale up to maximum 25 W. Power Supply Unit provides wide variations according to the power supply (100 to 240 V AC/ 24 V DC) status. The output contact during operation enables you to check the CPU operation. (CJ1W-PA205R only) Conforming to the SEMI-F47 Standard*. * AC input type, 200 V min. input.

Features of CJ1W-PA205C (with Maintenance Forecast Function)

Schedule Replacement and Replace Units before Their Service Life Ends The Power Supply Unit has a 6-level, 7-segment display on the front to indicate when the Unit should be replaced. It also outputs an alarm when the estimated remaining service life falls below 6 months. This enables Unit replacement before the end of its service life before the system goes down. It also makes it easier to plan Unit replacement, such as the lines or Racks where replacement is necessary and the number of Units to replace.   Same Wiring and Size as Current Power Supply Units Simply replace your current Power Supply Unit to add the maintenance forecast monitor function. The CJ1W-PA is the same size as the CJ1W-PA205R and the C200HW-PA204C is the same size as the C200HW-PA204.

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OMRON PLC CJ1W-PH41U (High-resolution Unit) and CJ1W-AD04U (General-purpose Unit)

Fully Integrated Sequence and Loop Control New Built-in Loop Controller Ultra-small size fits in most devices. Backplane-free structure provides the functions you need in minimum space. Low-cost solution for controlling multiple loops. Function block programming for easy engineering. HMI windows can be simply generated from function blocks automatically. Effective maintenance functions.

New Products

CJ1W-PH41U Process Analog I/O Unit (High-resolution Unit with Fully Universal Inputs) CJ1W-AD04U Process Analog I/O Unit (General-purpose Unit with Fully Universal Inputs) A single Unit handles all types of inputs, including temperature sensor inputs (e.g., thermocouple or platinum resistance thermometer), analog signal inputs (e.g., 4 to 20 mA or 1 to 5 V), and potentiometer inputs. Fully Universal Inputs, Including Thermocouple Inputs, Platinum Resistance Thermometer Inputs, and DC/Voltage Inputs The input type can be selected for each input channel, saving space and reducing costs for compact devices that use a mix of input types. And trouble-free selection of input types improves inventory control and maintenance. General-purpose Models for Great Cost Performance and High-resolution Models for Applications Such as Semiconductor Production Equipment These compact CJ-series Units provide four insolated input channels per Unit. Depending on the application, choose either the high-resolution CJ1W-PH41U, which provides a selection of combinations of resolutions and conversion speeds in addition to a PLC-first 1/1,000°C range (0.000 to 50.000°C, 4-wire Pt100), or the general-purpose CJ1W-AD04U, which provides superior cost performance. (See note.) Note: According to OMRON investigation. Resolutions and Sampling Speeds for High-resolution Models Resolution: 1/256,000 Resolution: 1/64,000 Resolution: 1/16,000 60 ms/4 points 10 ms/4 points 5 ms/4 points

Advantages of Smart Process Control

Advanced controller functions integrated with the same CJ-series functionality and high-speed capabilities Downsizing Ultra-small size fits in most devices. Backplane-free structure provides the functions you need in minimum space. Low-cost solution for controlling multiple loops. Easy Engineering Function block programming for easy engineering. Seamless integration of sequence control and loop control. HMI windows can be simply generated from function blocks automatically. High Reliability Control functions have the added ability to control multiple loops. Consolidating the proven CS-series loop-control technology. Effective maintenance functions.

Features

Integrated Loop Control and Sequence Control   An engine for controlling analog quantities (e.g., temperature, pressure, flowrate) is built into the same CPU Unit as the engine for executing sequence control, delivering high-speed sequence control and high-speed, advanced analog quantity control in a single Unit.       Small - Super compact: Only 90 mm High and 65 mm Deep, and Backplane-free structure enables flexible width design. Compact PLC Aids Machine Downsizing by Fitting Just About Anywhere. Wide Array of I/O Units, Special I/O Units, and CPU Bus Units Are Available to Suit Your Application.         Fast - High-speed sequence control functions can be used directly for high-speed, advanced loop control. Sequence control: Executes 20-Kstep ladder programs in 1 ms (with basic instructions only). PCMIX = 7.4 LD or OUT executed in 40 ns Loop control: Executes PID operations for 20 loops in up to 10 ms. This is a guide for general applications.       Easy - Function blocks make loop-control programming easy. You can also create CX-Process Tool tuning windows to help adjust loops. Controller faceplates can be created automatically for touch panel displays. Sequence control programs: Standardize and simplify programs using structured programming. Special I/O Unit and CPU Bus Unit settings are easy with function blocks (using ladder programming language or structured text). Loop control programs: By combining function blocks, a wide array of control methods can be easily configured, from basic PID control used by Temperature Controllers to program, cascade, and feed-forward control.       Expandability - Lineup includes low-cost models that use up to 50 function blocks and models that allow up to 300 blocks designed for large-scale systems and complicated operations. Loop control: Programming with function blocks to suit the application. System configuration: Choose and combine functions from a broad selection of I/O Units.       Maintenance - Simply turn the DIP Switch ON/OFF to save or read the user program including function blocks using the Memory Card. Simple backup function enables backup, recovery, and comparison of all PLC data including the function block programs for the Loop Control Board using the Memory Card. Save tag settings, comments, annotations, and connection data created using the CX-Process Tool to the Memory Card.       Result - Consolidating OMRON's expertise in temperature and process control cultivated over many years to provide you with effortless solutions using proven algorithms. Loop control: Proven functionality of Temperature Controllers and CS-series Loop Control Boards (see note 1) in a compact size.

Applications

The Loop-control CPU Unit Provides You with Solutions for the Complex and Advanced Functions Demanded by Control Devices in an Increasingly Diverse Range of Equipment. Providing Solutions to Other Problems

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